Jono has another idea brewing!!

[Timmy]

Cost is probably a major factor is mazda choosing cast ali. It maybe a sports car but it\'s no ferrari you could quickly double the manufacturing cost with small changes like that.

[shaunwil]

Cost is a huge factor. A cast part with some machining is still expensive but nothing like fabricated stuff. If you take the Rx8 intake system it probably costs mazda less than £10 to produce in plastic if you don\'t take the tooling costs into account (depends on complexity but I bet there isn\'t much change from £200k)

I think one of the big factors in the FD would be between steel and alloy because they would both be sandcast would be overall weight. They where trying in some places to make the engine as light as possible. Plus alloy is much quicker to machine than steel but more expensive metal to purchase !

Shaun

[snatchman]

Theres a picture of manifolds on FDUK

[leeroy_25]

When I mentioned High performance cars I meant a ferrari of porsche.. etc.. I am sure these also use ally intake manifolds?

[shaunwil]

Interesting read :

http://www.zcorp.com/en/Solutions/Castings--Patterns--Molds/spage.aspx

There are a couple of companies in the UK that can print moulds direct from 3D models in to aluminium. So any manifold could just be cast in alloy and finish machined !

Can\'t remember the names of the companies that offer the service. Looked into it when I was investigating a rapid prototype machine for work. The machine we own would make patterns for sand casting but would be expensive, about 30p per cm^3 but you can hollow shell patterns for reduced material required. Time is what makes these machines expensive because companies charge by the hour !

Shaun